Substrates and Laminates for Absorbent Articles

ABSTRACT

The present disclosure provides substrates and laminates for absorbent articles and absorbent articles comprising the substrates or laminates. The substrates and laminates may have three-dimensional elements, land areas, and increased permeability regions intermediate at least some of the land areas and at least some of the three-dimensional elements. The increased permeability regions may be positioned adjacent to the three-dimensional elements. The land areas may have a first basis weight and the increased permeability regions may have a second basis weight. The first basis weight may be greater than the second basis weight.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of, and claims priority under 35U.S.C. § 120 to, U.S. patent application Ser. No. 15/903,094, filed onFeb. 23, 2018, the entire disclosure of which is hereby incorporated byreference.

FIELD

The present disclosure is generally directed to substrates and laminatesfor absorbent articles and, is more specifically directed to, substratesand laminates comprising increased permeability regions for absorbentarticles.

BACKGROUND

Absorbent articles are used to contain and absorb bodily exudates (i.e.,urine, bowel movements, and menses). Absorbent articles may take on theform of diapers, pants, adult incontinence garments, sanitary napkins,and/or tampons, for example. These absorbent articles typically comprisea liquid permeable topsheet, a liquid impermeable backsheet, and anabsorbent core positioned at least partially intermediate the topsheetand the backsheet. The absorbent articles may also comprise anacquisition layer or a secondary topsheet positioned at least partiallyintermediate the topsheet and the absorbent core. In recent years,consumers have shown a desire towards topsheet substrates and/ortopsheet laminates, topsheet/acquisition layer laminates, ortopsheet/secondary topsheet laminates that have three-dimensionalelements. The substrates and/or laminates, at times, owing to theirthree-dimensional configuration and relatively high basis weight, mayhinder bodily exudate absorbency and have a wet feeling during use. Assuch, these substrates and/or laminates should be improved to betterwick bodily exudates therethrough.

SUMMARY

The present disclosure provides improved substrates and/or laminates forabsorbent articles and absorbent articles comprising the improvedsubstrates and/or laminates. The substrates and/or laminates maycomprise three-dimensional elements having improved texture definitionand/or more fibers in three-dimensional elements caused at least in partby less fiber breakage. The substrates and/or laminate may have betterbodily exudate acquisition owing to increased permeability regions inthe substrates and/or laminates. The substrates and/or laminates mayalso have a better balance of dryness and bodily exudate acquisitionthan previous substrates and/or laminates. Fast bodily exudateacquisition is even more important in the context of a hydrophobicwearer-facing layer. The substrates and/or laminates may employ at leastone layer of a through-air bonded nonwoven material or a lightly bonded(e.g., the bonds are able to at least partially break upon applicationof a force or the fibers can move relative to the bonds, such as whencreating three-dimensional elements) nonwoven material. The through-airbonded or lightly bonded nonwoven material may comprise carded fibernonwoven materials or continuous fiber nonwoven material, for example.The through-air bonded, or lightly bonded, nonwoven materials may allowfor fiber movement during three-dimensional element formation, therebyreducing fiber breakage and creating improved permeability regionsadjacent to the three-dimensional elements. The lightly bonded materialsmay have calendar or point bonds that allow fibers to move out of orrelative to the calendar or point bonds when one or more forces areapplied to a portion of the fibers, such as during three-dimensionalelement formation. As such, the lightly bonded calendar or point bondsmay allow for fiber movement without fiber thinning or breakage or withreduced fiber thinning or breakage. Through-air bonded nonwovenmaterials typically have fiber to fiber bonds and are free of calendaror point bonds. These through-air bonds are much weaker and easier tobreak compared to normal (i.e., not lightly bonded) calendar or pointbonds. As such, during three-dimensional element formation, thethrough-air bonds are easily able to break and allow for fiber movementwithout fiber breakage or with reduced fiber breakage. This fibermovement (whether in a through-air bonded nonwoven material or a lightlybonded nonwoven material) may allow for basis weight to be lowered inareas adjacent to the three-dimensional elements to provide increasedpermeability regions adjacent to the three-dimensional elements. Statedanother way, this fiber movement may allow for basis weight shifting inthe nonwoven materials adjacent to the three-dimensional elements.

The present disclosure is directed, in part, to laminates for absorbentarticles and absorbent articles comprising the laminates. The laminatesmay have two or more nonwoven materials, with at least one of thenonwoven materials being a through-air bonded nonwoven material. Thethrough-air bonded nonwoven material may comprise or be composed ofcarded or spunbond fibers and the other layer comprise or be composed ofcarded or spunbond fibers. Either of the layers may comprise nano fibersor meltblown fibers, for example. The laminates may havethree-dimensional elements, land areas comprising the fibers, andincreased permeability regions comprising the fibers and formed adjacentto the three-dimensional elements and positioned intermediate at leastsome of the land areas and at least some of the three-dimensionalelements. The increased permeability regions may have a lower basisweight than the land areas. A first nonwoven material may comprisenormal (i.e., not lightly bonded) calendar or point bonds and a secondnonwoven material may be free of normal calendar and point bonds and mayonly comprise fiber to fiber bonds. The second nonwoven material mayalso be a through-air bonded material that is free of normal calendarand point bonds. The laminates may comprise more than two nonwovenmaterials. The first and second nonwoven materials herein, including inthe claims, may be referred to as “first” and “second” depending onwhich one is discussed first.

The present disclosure is directed, in part, to a substrate for anabsorbent article. The substrate may comprise a nonwoven materialcomprising fibers. The nonwoven material may comprise a lightly bondedmaterial having calendar or point bonds or may comprise a through-airbonded material comprising through-air bonds and being free of normalcalendar or point bonds.

The fibers may be spunbond fibers or carded fibers. The nonwovenmaterial may comprise three-dimensional elements, land areas comprisingthe fibers and positioned in areas free of the three-dimensionalelements, and increased permeability regions comprising the fiber andpositioned adjacent to at least some of the three-dimensional elements.In the land areas, the nonwoven material has a first basis weight,according to the Micro-CT Test herein. In the increased permeabilityregions, the nonwoven material has a second basis weight in the range ofless than 75% to less than 25% (or other ranges herein), of the firstbasis weight of the land areas, according to the Micro-CT Test herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of the presentdisclosure, and the manner of attaining them, will become more apparentand the disclosure itself will be better understood by reference to thefollowing description of example forms of the disclosure taken inconjunction with the accompanying drawings, wherein:

FIG. 1 is a plan view of an example absorbent article in the form of ataped diaper, garment-facing surface facing the viewer, in a flatlaid-out state;

FIG. 2 is a plan view of the example absorbent article of FIG. 1,wearer-facing surface facing the viewer, in a flat laid-out state;

FIG. 3 is a front perspective view of the absorbent article of FIGS. 1and 2 in a fastened position;

FIG. 4 is a front perspective view of an absorbent article in the formof a pant;

FIG. 5 is a rear perspective view of the absorbent article of FIG. 4;

FIG. 6 is a plan view of the absorbent article of FIG. 4, laid flat,with a garment-facing surface facing the viewer;

FIG. 7 is a cross-sectional view of the absorbent article taken aboutline 7-7 of FIG. 6;

FIG. 8 is a cross-sectional view of the absorbent article taken aboutline 8-8 of FIG. 6;

FIG. 9 is a plan view of an example absorbent core or an absorbentarticle;

FIG. 10 is a cross-sectional view, taken about line 10-10, of theabsorbent core of FIG. 9;

FIG. 11 is a cross-sectional view, taken about line 11-11, of theabsorbent core of FIG. 10;

FIG. 12 is a plan view of an example absorbent article of the presentdisclosure that is a sanitary napkin;

FIG. 13 is an example cross-sectional view taken within a front waistregion of an absorbent article;

FIG. 14 is an example cross-sectional view taken within a crotch regionof an absorbent article;

FIG. 15 is an example cross-sectional view taken within a back waistregion of an absorbent article;

FIG. 16 is a cross-sectional schematic illustration of an examplelaminate of the present disclosure comprising two nonwoven materials;

FIG. 16A is a cross-sectional schematic illustration of an examplesubstrate of the present disclosure comprising a nonwoven material;

FIG. 17 is a cross-sectional schematic illustration of another examplelaminate of the present disclosure comprising three nonwoven materials;

FIG. 18 is a cross-sectional schematic illustration of another examplelaminate of the present disclosure comprising two nonwoven materials;

FIG. 19 is a cross-sectional schematic illustration of another examplelaminate of the present disclosure comprising two nonwoven materials;

FIG. 19A is a cross-sectional schematic illustration of an examplesubstrate of the present disclosure comprising a nonwoven material;

FIG. 20 is a top view photograph of a calendar or point bonded nonwovenmaterial for use in the laminates of the present disclosure;

FIG. 21 is a cross-sectional photograph taken about line 21-21 of FIG.20 and illustrating the calendar or point bond;

FIG. 22 is a side view photograph of a through-air bonded nonwovenmaterial for use in the laminates of the present disclosure;

FIG. 23 is a cross-sectional photograph taken about line 23-23 of FIG.22 and illustrating through-air bonds;

FIG. 24 is a bottom perspective view of another example laminate of thepresent disclosure;

FIG. 25 is an exploded view of circle 25 of FIG. 24;

FIG. 26 is a top perspective view photograph of an example substrate ofthe present disclosure comprising a nonwoven material having increasedpermeability regions; and

FIG. 27 is a top perspective view photograph of a comparative examplesubstrate that does not comprise the increased permeability regions ofthe present disclosure. The comparative example substrate is a 25 gsmspunbond PE/PP bicomponent nonwoven material comprising calendar bonds.

DETAILED DESCRIPTION

Various non-limiting forms of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of the substrates andlaminates for absorbent articles disclosed herein. One or more examplesof these non-limiting forms are illustrated in the accompanyingdrawings. Those of ordinary skill in the art will understand that thesubstrates and laminates for absorbent articles described herein andillustrated in the accompanying drawings are non-limiting example formsand that the scope of the various non-limiting forms of the presentdisclosure are defined solely by the claims. The features illustrated ordescribed in connection with one non-limiting form may be combined withthe features of other non-limiting forms. Such modifications andvariations are intended to be included within the scope of the presentdisclosure.

Initially, a general description of example absorbent articles will beprovided and then the substrates and/or laminates for absorbent articlesor other consumer products will be discussed. The substrates (i.e.,single layer) for absorbent articles may form a topsheet, an acquisitionlayer, a distribution layer, a secondary topsheet, a core cover, othersuitable layer, or a substrate in a consumer products other thanabsorbent articles. The laminates (i.e., more than one layer) forabsorbent articles may form a topsheet laminate, a topsheet/acquisitionlayer laminate, a topsheet/secondary topsheet laminate, an outer covernonwoven material laminate, another laminate for other components ofabsorbent articles, or laminates for consumer products other thanabsorbent articles, for example.

General Description of an Absorbent Article

An example absorbent article 10 according to the present disclosure,shown in the form of a taped diaper, is represented in FIGS. 1-3. FIG. 1is a plan view of the example absorbent article 10, garment-facingsurface 2 facing the viewer in a flat, laid-out state (i.e., no elasticcontraction). FIG. 2 is a plan view of the example absorbent article 10of FIG. 1, wearer-facing surface 4 facing the viewer in a flat, laid-outstate. FIG. 3 is a front perspective view of the absorbent article 10 ofFIGS. 1 and 2 in a fastened configuration. The absorbent article 10 ofFIGS. 1-3 is shown for illustration purposes only as the presentdisclosure may be used for making a wide variety of diapers, includingadult incontinence products, pants, or other absorbent articles, such assanitary napkins and absorbent pads, for example.

The absorbent article 10 may comprise a front waist region 12, a crotchregion 14, and a back waist region 16. The crotch region 14 may extendintermediate the front waist region 12 and the back waist region 16. Thefront wait region 12, the crotch region 14, and the back waist region 16may each be ⅓ of the length of the absorbent article 10. The absorbentarticle 10 may comprise a front end edge 18, a back end edge 20 oppositeto the front end edge 18, and longitudinally extending, transverselyopposed side edges 22 and 24 defined by the chassis 52.

The absorbent article 10 may comprise a liquid permeable topsheet 26, aliquid impermeable backsheet 28, and an absorbent core 30 positioned atleast partially intermediate the topsheet 26 and the backsheet 28. Theabsorbent article 10 may also comprise one or more pairs of barrier legcuffs 32 with or without elastics 33, one or more pairs of leg elastics34, one or more elastic waistbands 36, and/or one or more acquisitionmaterials 38. The acquisition material or materials 38 may be positionedintermediate the topsheet 26 and the absorbent core 30. An outer covermaterial 40, such as a nonwoven material, may cover a garment-facingside of the backsheet 28. The absorbent article 10 may comprise backears 42 in the back waist region 16. The back ears 42 may comprisefasteners 46 and may extend from the back waist region 16 of theabsorbent article 10 and attach (using the fasteners 46) to the landingzone area or landing zone material 44 on a garment-facing portion of thefront waist region 12 of the absorbent article 10. The absorbent article10 may also have front ears 47 in the front waist region 12. Theabsorbent article 10 may have a central lateral (or transverse) axis 48and a central longitudinal axis 50. The central lateral axis 48 extendsperpendicular to the central longitudinal axis 50.

In other instances, the absorbent article may be in the form of a panthaving permanent or refastenable side seams. Suitable refastenable seamsare disclosed in U.S. Pat. Appl. Pub. No. 2014/0005020 and U.S. Pat. No.9,421,137. Referring to FIGS. 4-8, an example absorbent article 10 inthe form of a pant is illustrated. FIG. 4 is a front perspective view ofthe absorbent article 10. FIG. 5 is a rear perspective view of theabsorbent article 10. FIG. 6 is a plan view of the absorbent article 10,laid flat, with the garment-facing surface facing the viewer. Elementsof FIG. 4-8 having the same reference number as described above withrespect to FIGS. 1-3 may be the same element (e.g., absorbent core 30).FIG. 7 is an example cross-sectional view of the absorbent article takenabout line 7-7 of FIG. 6. FIG. 8 is an example cross-sectional view ofthe absorbent article taken about line 8-8 of FIG. 6. FIGS. 7 and 8illustrate example forms of front and back belts 54, 56. The absorbentarticle 10 may have a front waist region 12, a crotch region 14, and aback waist region 16. Each of the regions 12, 14, and 16 may be ⅓ of thelength of the absorbent article 10. The absorbent article 10 may have achassis 52 (sometimes referred to as a central chassis or central panel)comprising a topsheet 26, a backsheet 28, and an absorbent core 30disposed at least partially intermediate the topsheet 26 and thebacksheet 28, and an optional acquisition material 38, similar to thatas described above with respect to FIGS. 1-3. The absorbent article 10may comprise a front belt 54 in the front waist region 12 and a backbelt 56 in the back waist region 16. The chassis 52 may be joined to awearer-facing surface 4 of the front and back belts 54, 56 or to agarment-facing surface 2 of the belts 54, 56. Side edges 23 and 25 ofthe front belt 54 may be joined to side edges 27 and 29, respectively,of the back belt 56 to form two side seams 58. The side seams 58 may beany suitable seams known to those of skill in the art, such as buttseams or overlap seams, for example. When the side seams 58 arepermanently formed or refastenably closed, the absorbent article 10 inthe form of a pant has two leg openings 60 and a waist openingcircumference 62. The side seams 58 may be permanently joined usingadhesives or bonds, for example, or may be refastenably closed usinghook and loop fasteners, for example.

Belts

Referring to FIGS. 7 and 8, the front and back belts 54 and 56 maycomprise front and back inner belt layers 66 and 67 and front and backouter belt layers 64 and 65 having an elastomeric material (e.g.,strands 68 or a film (which may be apertured)) disposed at leastpartially therebetween. The elastic elements 68 or the film may berelaxed (including being cut) to reduce elastic strain over theabsorbent core 30 or, may alternatively, run continuously across theabsorbent core 30. The elastics elements 68 may have uniform or variablespacing therebetween in any portion of the belts. The elastic elements68 may also be pre-strained the same amount or different amounts. Thefront and/or back belts 54 and 56 may have one or more elastic elementfree zones 70 where the chassis 52 overlaps the belts 54, 56. In otherinstances, at least some of the elastic elements 68 may extendcontinuously across the chassis 52.

The front and back inner belt layers 66, 67 and the front and back outerbelt layers 64, 65 may be joined using adhesives, heat bonds, pressurebonds or thermoplastic bonds. Various suitable belt layer configurationscan be found in U.S. Pat. Appl. Pub. No. 2013/0211363.

Front and back belt end edges 55 and 57 may extend longitudinally beyondthe front and back chassis end edges 19 and 21 (as shown in FIG. 6) orthey may be co-terminus. The front and back belt side edges 23, 25, 27,and 29 may extend laterally beyond the chassis side edges 22 and 24. Thefront and back belts 54 and 56 may be continuous (i.e., having at leastone layer that is continuous) from belt side edge to belt side edge(e.g., the transverse distances from 23 to 25 and from 27 to 29).Alternatively, the front and back belts 54 and 56 may be discontinuousfrom belt side edge to belt side edge (e.g., the transverse distancesfrom 23 to 25 and 27 to 29), such that they are discrete.

As disclosed in U.S. Pat. No. 7,901,393, the longitudinal length (alongthe central longitudinal axis 50) of the back belt 56 may be greaterthan the longitudinal length of the front belt 54, and this may beparticularly useful for increased buttocks coverage when the back belt56 has a greater longitudinal length versus the front belt 54 adjacentto or immediately adjacent to the side seams 58.

The front outer belt layer 64 and the back outer belt layer 65 may beseparated from each other, such that the layers are discrete or,alternatively, these layers may be continuous, such that a layer runscontinuously from the front belt end edge 55 to the back belt end edge57. This may also be true for the front and back inner belt layers 66and 67—that is, they may also be longitudinally discrete or continuous.Further, the front and back outer belt layers 64 and 65 may belongitudinally continuous while the front and back inner belt layers 66and 67 are longitudinally discrete, such that a gap is formed betweenthem—a gap between the front and back inner and outer belt layers 64,65, 66, and 67 is shown in FIG. 7 and a gap between the front and backinner belt layers 66 and 67 is shown in FIG. 8.

The front and back belts 54 and 56 may include slits, holes, and/orperforations providing increased breathability, softness, and agarment-like texture. Underwear-like appearance can be enhanced bysubstantially aligning the waist and leg edges at the side seams 58 (seeFIGS. 4 and 5).

The front and back belts 54 and 56 may comprise graphics (see e.g., 78of FIG. 1). The graphics may extend substantially around the entirecircumference of the absorbent article 10 and may be disposed acrossside seams 58 and/or across proximal front and back belt seams 15 and17; or, alternatively, adjacent to the seams 58, 15, and 17 in themanner described in U.S. Pat. No. 9,498,389 to create a moreunderwear-like article. The graphics may also be discontinuous.

Alternatively, instead of attaching belts 54 and 56 to the chassis 52 toform a pant, discrete side panels may be attached to side edges of thechassis 22 and 24. Suitable forms of pants comprising discrete sidepanels are disclosed in U.S. Pat. Nos. 6,645,190; 8,747,379; 8,372,052;8,361,048; 6,761,711; 6,817,994; 8,007,485; 7,862,550; 6,969,377;7,497,851; 6,849,067; 6,893,426; 6,953,452; 6,840,928; 8,579,876;7,682,349; 7,156,833; and 7,201,744.

Topsheet

The topsheet 26 is the part of the absorbent article 10 that is incontact with the wearer's skin. The topsheet 26 may be joined toportions of the backsheet 28, the absorbent core 30, the barrier legcuffs 32, and/or any other layers as is known to those of ordinary skillin the art. The topsheet 26 may be compliant, soft-feeling, andnon-irritating to the wearer's skin. Further, at least a portion of, orall of, the topsheet may be liquid permeable, permitting liquid bodilyexudates to readily penetrate through its thickness. A suitable topsheetmay be manufactured from continuous fibers (e.g., spunbond), cardedfibers, cotton fibers, other natural fibers, for example. The topsheetmay comprise through-air bonded nonwoven materials, through-air bondednonwoven materials and calendar bonded nonwoven materials, as will bediscussed further below. The topsheet may have one or more layers and bea laminate (as discussed below). Some topsheet are apertured (FIG. 2,element 27). Any portion of the topsheet may be coated with a skin carecomposition, an antibacterial agent, a surfactant, and/or otherbeneficial agents. The topsheet may be hydrophilic or hydrophobic or mayhave hydrophilic and/or hydrophobic portions or layers. If the topsheetis hydrophobic, in some instances, apertures may be present so thatbodily exudates may pass through the topsheet.

The topsheet may be one of the example laminates discussed below or mayform a portion of the laminate in combination with an acquisitionmaterial or layer, a secondary topsheet, or another layer or material,for example.

Backsheet

The backsheet 28 is generally that portion of the absorbent article 10positioned proximate to the garment-facing surface of the absorbent core30. The backsheet 28 may be joined to portions of the topsheet 26, theouter cover material 40, the absorbent core 30, and/or any other layersof the absorbent article by any attachment methods known to those ofskill in the art. The backsheet 28 prevents, or at least inhibits, thebodily exudates absorbed and contained in the absorbent core 10 fromsoiling articles such as bedsheets, undergarments, and/or clothing. Thebacksheet is typically liquid impermeable, or at least substantiallyliquid impermeable. The backsheet may, for example, be or comprise athin plastic film, such as a thermoplastic film having a thickness ofabout 0.012 mm to about 0.051 mm. Other suitable backsheet materials mayinclude breathable materials which permit vapors to escape from theabsorbent article, while still preventing, or at least inhibiting,bodily exudates from passing through the backsheet.

Outer Cover Material

The outer cover material (sometimes referred to as a backsheet nonwoven)40 may comprise one or more nonwoven materials joined to the backsheet28 and that covers the backsheet 28. The outer cover material 40 formsat least a portion of the garment-facing surface 2 of the absorbentarticle 10 and effectively “covers” the backsheet 28 so that film is notpresent on the garment-facing surface 2. The outer cover material 40 maycomprise a bond pattern, apertures, and/or three-dimensional elements.The outer cover material may comprise the laminates discussed herein.

Absorbent Core

As used herein, the term “absorbent core” 30 refers to the component ofthe absorbent article 10 having the most absorbent capacity and thatcomprises an absorbent material. Referring to FIGS. 9-11, in someinstances, absorbent material 72 may be positioned within a core bag ora core wrap 74. The absorbent material may be profiled or not profiled,depending on the specific absorbent article. The absorbent core 30 maycomprise, consist essentially of, or consist of, a core wrap, absorbentmaterial 72, and glue enclosed within the core wrap. The absorbentmaterial may comprise superabsorbent polymers, a mixture ofsuperabsorbent polymers and air felt, only air felt, and/or a highinternal phase emulsion foam. In some instances, the absorbent materialmay comprise at least 80%, at least 85%, at least 90%, at least 95%, atleast 99%, or up to 100% superabsorbent polymers, by weight of theabsorbent material. In such instances, the absorbent material may freeof air felt, or at least mostly free of air felt. The absorbent coreperiphery, which may be the periphery of the core wrap, may define anysuitable shape, such as rectangular “T,” “Y,” “hour-glass,” or“dog-bone” shaped, for example. An absorbent core periphery having agenerally “dog bone” or “hour-glass” shape may taper along its widthtowards the crotch region 14 of the absorbent article 10.

Referring to FIGS. 9-11, the absorbent core 30 may have areas havinglittle or no absorbent material 72, where a wearer-facing surface of thecore bag 74 may be joined to a garment-facing surface of the core bag74. These areas having little or no absorbent material may be referredto as “channels” 76. These channels can embody any suitable shapes andany suitable number of channels may be provided. In other instances, theabsorbent core may be embossed to create the impression of channels. Theabsorbent core in FIGS. 9-11 is merely an example absorbent core. Manyother absorbent cores with or without channels are also within the scopeof the present disclosure.

Barrier Leg Cuffs/Leg Elastics

Referring to FIGS. 1 and 2, for example, the absorbent article 10 maycomprise one or more pairs of barrier leg cuffs 32 and one or more pairsof leg elastics 34. The barrier leg cuffs 32 may be positioned laterallyinboard of leg elastics 34. Each barrier leg cuff 32 may be formed by apiece of material which is bonded to the absorbent article 10 so it canextend upwards from a wearer-facing surface 4 of the absorbent article10 and provide improved containment of body exudates approximately atthe junction of the torso and legs of the wearer. The barrier leg cuffs32 are delimited by a proximal edge joined directly or indirectly to thetopsheet and/or the backsheet and a free terminal edge, which isintended to contact and form a seal with the wearer's skin. The barrierleg cuffs 32 may extend at least partially between the front end edge 18and the back end edge 20 of the absorbent article 10 on opposite sidesof the central longitudinal axis 50 and may be at least present in thecrotch region 14. The barrier leg cuffs 32 may each comprise one or moreelastics 33 (e.g., elastic strands or strips) near or at the freeterminal edge. These elastics 33 cause the barrier leg cuffs 32 to helpform a seal around the legs and torso of a wearer. The leg elastics 34extend at least partially between the front end edge 18 and the back endedge 20. The leg elastics 34 essentially cause portions of the absorbentarticle 10 proximate to the chassis side edges 22, 24 to help form aseal around the legs of the wearer. The leg elastics 34 may extend atleast within the crotch region 14.

Elastic Waistband

Referring to FIGS. 1 and 2, the absorbent article 10 may comprise one ormore elastic waistbands 36. The elastic waistbands 36 may be positionedon the garment-facing surface 2 or the wearer-facing surface 4. As anexample, a first elastic waistband 36 may be present in the front waistregion 12 near the front belt end edge 18 and a second elastic waistband36 may be present in the back waist region 16 near the back end edge 20.The elastic waistbands 36 may aid in sealing the absorbent article 10around a waist of a wearer and at least inhibiting bodily exudates fromescaping the absorbent article 10 through the waist openingcircumference. In some instances, an elastic waistband may fullysurround the waist opening circumference of an absorbent article.

Acquisition Materials

Referring to FIGS. 1, 2, 7, and 8, one or more acquisition materials 38may be present at least partially intermediate the topsheet 26 and theabsorbent core 30. The acquisition materials 38 are typicallyhydrophilic materials that provide significant wicking of bodilyexudates. These materials may dewater the topsheet 26 and quickly movebodily exudates into the absorbent core 30. The acquisition materials 38may comprise one or more nonwoven materials, foams, cellulosicmaterials, cross-linked cellulosic materials, air laid cellulosicnonwoven materials, spunlace materials, or combinations thereof, forexample. In some instances, portions of the acquisition materials 38 mayextend through portions of the topsheet 26, portions of the topsheet 26may extend through portions of the acquisition materials 38, and/or thetopsheet 26 may be nested with the acquisition materials 38. Typically,an acquisition material 38 may have a width and length that are smallerthan the width and length of the topsheet 26. The acquisition materialmay be a secondary topsheet in the feminine pad context. The acquisitionmaterial may have one or more channels as described above with referenceto the absorbent core 30 (including the embossed version). The channelsin the acquisition material may align or not align with channels in theabsorbent core 30. In an example, a first acquisition material maycomprise a nonwoven material and as second acquisition material maycomprise a cross-linked cellulosic material.

In the context of the laminates discussed herein, the acquisitionmaterials may be combined with a topsheet to form the laminates.

Landing Zone

Referring to FIGS. 1 and 2, the absorbent article 10 may have a landingzone area 44 that is formed in a portion of the garment-facing surface 2of the outer cover material 40. The landing zone area 44 may be in theback waist region 16 if the absorbent article 10 fastens from front toback or may be in the front waist region 12 if the absorbent article 10fastens back to front. In some instances, the landing zone 44 may be ormay comprise one or more discrete nonwoven materials that are attachedto a portion of the outer cover material 40 in the front waist region 12or the back waist region 16 depending upon whether the absorbent articlefastens in the front or the back. In essence, the landing zone 44 isconfigured to receive the fasteners 46 and may comprise, for example, aplurality of loops configured to be engaged with, a plurality of hookson the fasteners 46, or vice versa.

Wetness Indicator/Graphics

Referring to FIG. 1, the absorbent articles 10 of the present disclosuremay comprise graphics 78 and/or wetness indicators 80 that are visiblefrom the garment-facing surface 2. The graphics 78 may be printed on thelanding zone 40, the backsheet 28, and/or at other locations. Thewetness indicators 80 are typically applied to the absorbent core facingside of the backsheet 28, so that they can be contacted by bodilyexudates within the absorbent core 30. In some instances, the wetnessindicators 80 may form portions of the graphics 78. For example, awetness indicator may appear or disappear and create/remove a characterwithin some graphics. In other instances, the wetness indicators 80 maycoordinate (e.g., same design, same pattern, same color) or notcoordinate with the graphics 78.

Front and Back Ears

Referring to FIGS. 1 and 2, as referenced above, the absorbent article10 may have front and/or back ears 47, 42 in a taped diaper context.Only one set of ears may be required in most taped diapers. The singleset of ears may comprise fasteners 46 configured to engage the landingzone or landing zone area 44. If two sets of ears are provided, in mostinstances, only one set of the ears may have fasteners 46, with theother set being free of fasteners. The ears, or portions thereof, may beelastic or may have elastic panels. In an example, an elastic film orelastic strands may be positioned intermediate a first nonwoven materialand a second nonwoven material. The elastic film may or may not beapertured. The ears may be shaped. The ears may be integral (e.g.,extension of the outer cover material 40, the backsheet 28, and/or thetopsheet 26) or may be discrete components attached to a chassis 52 ofthe absorbent article on a wearer-facing surface 4, on thegarment-facing surface 2, or intermediate the two surfaces 4, 2.

Sensors

Referring again to FIG. 1, the absorbent articles of the presentdisclosure may comprise a sensor system 82 for monitoring changes withinthe absorbent article 10. The sensor system 82 may be discrete from orintegral with the absorbent article 10. The absorbent article 10 maycomprise sensors that can sense various aspects of the absorbent article10 associated with insults of bodily exudates such as urine and/or BM(e.g., the sensor system 82 may sense variations in temperature,humidity, presence of ammonia or urea, various vapor components of theexudates (urine and feces), changes in moisture vapor transmissionthrough the absorbent articles garment-facing layer, changes intranslucence of the garment-facing layer, and/or color changes throughthe garment-facing layer). Additionally, the sensor system 82 may sensecomponents of urine, such as ammonia or urea and/or byproducts resultingfrom reactions of these components with the absorbent article 10. Thesensor system 82 may sense byproducts that are produced when urine mixeswith other components of the absorbent article 10 (e.g., adhesives,agm). The components or byproducts being sensed may be present as vaporsthat may pass through the garment-facing layer. It may also be desirableto place reactants in the absorbent article that change state (e.g.color, temperature) or create a measurable byproduct when mixed withurine or BM. The sensor system 82 may also sense changes in pH,pressure, odor, the presence of gas, blood, a chemical marker or abiological marker or combinations thereof. The sensor system 82 may havea component on or proximate to the absorbent article that transmits asignal to a receiver more distal from the absorbent article, such as aniPhone, for example. The receiver may output a result to communicate tothe caregiver a condition of the absorbent article 10. In otherinstances, a receiver may not be provided, but instead the condition ofthe absorbent article 10 may be visually or audibly apparent from thesensor on the absorbent article.

Packages

The absorbent articles of the present disclosure may be placed intopackages. The packages may comprise polymeric films and/or othermaterials. Graphics and/or indicia relating to properties of theabsorbent articles may be formed on, printed on, positioned on, and/orplaced on outer portions of the packages. Each package may comprise aplurality of absorbent articles. The absorbent articles may be packedunder compression so as to reduce the size of the packages, while stillproviding an adequate amount of absorbent articles per package. Bypackaging the absorbent articles under compression, caregivers caneasily handle and store the packages, while also providing distributionsavings to manufacturers owing to the size of the packages.

Sanitary Napkin

Referring to FIG. 12, an absorbent article of the present disclosure maybe a sanitary napkin 110. The sanitary napkin 110 may comprise a liquidpermeable topsheet 114, a liquid impermeable, or substantially liquidimpermeable, backsheet 116, and an absorbent core 118. The liquidimpermeable backsheet 116 may or may not be vapor permeable. Theabsorbent core 118 may have any or all of the features described hereinwith respect to the absorbent core 30 and, in some forms, may have asecondary topsheet 119 (STS) instead of the acquisition materialsdisclosed above. The STS 119 may comprise one or more channels, asdescribed above (including the embossed version). In some forms,channels in the STS 119 may be aligned with channels in the absorbentcore 118. The sanitary napkin 110 may also comprise wings 120 extendingoutwardly with respect to a longitudinal axis 180 of the sanitary napkin110. The sanitary napkin 110 may also comprise a lateral axis 190. Thewings 120 may be joined to the topsheet 114, the backsheet 116, and/orthe absorbent core 118. The sanitary napkin 110 may also comprise afront edge 122, a back edge 124 longitudinally opposing the front edge122, a first side edge 126, and a second side edge 128 longitudinallyopposing the first side edge 126. The longitudinal axis 180 may extendfrom a midpoint of the front edge 122 to a midpoint of the back edge124. The lateral axis 190 may extend from a midpoint of the first sideedge 128 to a midpoint of the second side edge 128. The sanitary napkin110 may also be provided with additional features commonly found insanitary napkins as is known in the art.

The secondary topsheet may be combined with a topsheet to form thelaminates discussed herein. In other instances, the laminates discussedherein may only form the topsheet of a sanitary napkin.

Examples Cross-Sectional Views of Absorbent Articles

FIGS. 13-15 illustrate example cross-sectional views of absorbentarticles within the scope of the present disclosure. FIG. 13 is anexample cross-sectional view taken within a front waist region 12 of anabsorbent article. FIG. 14 is an example cross-sectional view takenwithin a crotch region 14 of an absorbent article. FIG. 15 is an examplecross-sectional view taken within a back waist region 16 of an absorbentarticle. In FIGS. 13-15, an outer cover material is element 40, a liquidpermeable topsheet is element 26, opacity patches are elements 84, aliquid impermeable backsheet is element 28, an absorbent core is element30, with the core bag being element 74, an absorbent material is element72, and a distribution material is element 86. The distribution material86 may comprise cross-linked cellulosic material and may be optional. Anacquisition material is element 88. A liquid permeable topsheet iselement 26. Barrier leg cuffs are elements 90. Elastics in the barrierleg cuffs are elements 92. Back ears are elements 42. Fasteners on theback ears 42 are elements 46. Construction glues and/or bonds betweenthe various layers and/or components have been removed for clarity.Other cross-sectional configurations known to those of skill in the artare also within the scope of the present disclosure.

Substrates and/or Laminates for Absorbent Articles

Substrates and/or laminates for absorbent articles or other consumerproducts are provided herein. The substrates may comprise a through-airbonded nonwoven material or a lightly bonded nonwoven material. Theabsorbent articles discussed herein may comprise the substrates as atopsheet, an acquisition material, a secondary topsheet, an outer covernonwoven, and/or other components, for example. The absorbent articlesdiscussed herein may comprise the laminates as a topsheet laminate, atopsheet/acquisition material laminate, a topsheet/secondary topsheetlaminate, a topsheet and other material laminate, an outer covernonwoven material laminate, and/or other components, for example. Thelaminates may comprise two or more nonwoven materials, with at least oneof the nonwoven materials being through-air bonded and free of normalcalendar or point bonds. The substrates and/or laminates may also beused as wipes, cleaning or dusting substrates, or in other consumerproducts that comprise nonwoven materials. In some instances, thesubstrates and/or laminates may comprise wet-laid nonwoven materials,air-laid nonwoven materials, meltblown nonwoven materials, nano-fibernonwoven materials, spunbond nonwoven materials, carded nonwovenmaterials, spunlace nonwoven materials, or combinations of the same.

FIGS. 16-19 are schematic cross-sectional examples of portions oflaminates of the present disclosure. FIGS. 16-19 also illustrate thesubstrates (i.e., single layer) of the present disclosure (essentiallyremove the materials without the increased permeability regions). It isto be understood that the substrates may be used/manufacturedindependently of the laminates by only providing a single layersubstrate with increased permeability regions (see FIGS. 16A and 19Ashowing only the one nonwoven material from FIGS. 16 and 19,respectively). The substrates 201 of FIGS. 16A and 19A will be describedfurther below.

The laminates 200 may comprise a first nonwoven material 202 and asecond nonwoven material 204. Any of the laminates discussed herein mayalso comprise at least a third nonwoven material 206, although onlyillustrated in the laminate 200 of FIG. 17. The laminates 200 maycomprise a plurality of three-dimensional elements 208. Thethree-dimensional elements 208 may extend upward (e.g., FIGS. 16 and 17,toward a wearer) or downward (e.g., FIGS. 18 and 19, away from awearer). The three-dimensional elements 208 may be tufts, projections,and/or raised or depressed regions and may have any suitable shapes(such as ovate, circular, for example), heights, widths, and/or areas.The laminates 200 may comprise land areas 210 and increased permeabilityregions 212. The land areas 210 may be present in the laminates 200 inareas free of the three-dimensional elements 208 and free of theincreased permeability regions 212. The land areas 210 are essentiallyportions of the laminates that are not subjected to the strains ofthree-dimensional element formation and remain generally planar andunchanged in basis weight. The laminates 200 may comprise the increasedpermeability regions 212 adjacent to the three-dimensional elements 208.These increased permeability regions 212 are illustrated in dash inFIGS. 16-19A. The increased permeability regions 212 are essentiallyareas of low basis weight (relative to the remainder of the nonwovenmaterials, such as the land areas 210) in the first or second nonwovenmaterials, although they could exist in both of or more than two of thenonwoven materials. In some instances, areas of low basis weight mayonly exist in a through-air bonded nonwoven material or a light bondednonwoven material and not in a normal calendar bonded or point bondednonwoven material.

FIG. 16 illustrates a portion of the second nonwoven material 204extending through the first nonwoven material 202 to form athree-dimensional element 208 in the laminate 200. The second nonwovenmaterial 204 may also be a substrate of the present disclosure. A firstsurface 214 of the laminate 200 may comprise portions of the firstnonwoven material 202 and portions of the second nonwoven material 204,while the second surface 216 may only comprise the second nonwovenmaterial 204. In such an instance, the second nonwoven material 204 maycomprise the increased permeability regions 212 adjacent to thethree-dimensional elements 208. FIG. 18 illustrates a portion of thefirst nonwoven material 202 extending through the second nonwovenmaterial 204. In such an instance, the second surface 216 of thelaminate may comprise portions of the first nonwoven material 202 andportions of the second nonwoven material 204, while the first surface214 may only comprise the first nonwoven material 202. In such aninstance, the first nonwoven material 202 may comprise the increasedpermeability regions 212 adjacent to the three-dimensional elements 208.

FIG. 17 illustrates a portion of the second nonwoven material 204, andoptionally a third nonwoven material or material 206 (such as a film ora nonwoven), nested with the first nonwoven material 202 to form athree-dimensional element 208. In such an instance, the increasedpermeability regions 212 may be formed in at least the second nonwovenmaterial 204 adjacent to the three-dimensional elements 208, andpossibly in the first nonwoven material 202 in similar locations as thesecond nonwoven material 204. FIG. 19 illustrates a portion of the firstnonwoven material 202 nested with the second nonwoven material 204 toform a three-dimensional element 208. In such an instance, the increasedpermeability regions 212 may be formed in at least the first nonwovenmaterial 202 adjacent to the three-dimensional elements 208, andpossibly in the second nonwoven material 204 in similar locations as thefirst nonwoven material 202.

FIG. 16A illustrates an example substrate 201 taken from FIG. 16. Thesubstrate 201 is the second nonwoven material 204 of FIG. 16. Thesubstrate 201 has a first surface 213 and second surface 215. Thesubstrate 201 comprises three-dimensional elements 208′, land areas210′, and increased permeability regions 212′. The increasedpermeability regions 212′ may be positioned adjacent to at least some ofthe three-dimensional elements 208′. In the land areas 210′, thenonwoven material has a first basis weight, according to the Micro-CTTest. In the increased permeability regions 212′, the nonwoven materialhas a second basis weight in the range of less than 75% to less than 25%of the first basis weight of the land areas. The three-dimensionalelements 208′ of the example substrate 201 of FIG. 16A may extendupwardly (as illustrated) or downwardly. Other details discussed hereinmay apply to the substrate 201, such a material choices, fiber types,bonds etc.

FIG. 19A illustrates an example substrate 201 taken from FIG. 19. Thesubstrate 201 is the first nonwoven material 202 of FIG. 19. Thesubstrate 201 has a first surface 213 and second surface 215. Thesubstrate 201 comprises three-dimensional elements 208′, land areas210′, and increased permeability regions 212′. The increasedpermeability regions 212′ may be positioned adjacent to at least some ofthe three-dimensional elements 208′. In the land areas 210′, thenonwoven material has a first basis weight, according to the Micro-CTTest. In the increased permeability regions 212′, the nonwoven materialhas a second basis weight in the range of less than 75% to less than 25%of the first basis weight of the land areas. The three-dimensionalelements 208′ of the example substrate 201 of FIG. 19A may extenddownwardly (as illustrated) or upwardly. Other details discussed hereinmay apply to the substrate 201, such as material choices, fibers types,bonds etc.

FIG. 20 illustrates a top view photograph of a calendar or point bondednonwoven material 218 that may be used in the laminates described hereinas one or more of the nonwoven materials. FIG. 21 is a cross-sectionalschematic illustration taken about line 21-21 of FIG. 20. FIG. 21illustrates a calendar or point bond 220 surrounded by unbonded fibers219. The calendar or point bonds 220 are essentially highly densifiedregions within the nonwoven material 218 and are sometimes referred toherein as “normal calendar or point bonds.” These normal calendar orpoint bonds typically have uniform sizes, shapes, and are uniformlyspaced relative to each other. The normal calendar or point bonds 220may be used during the nonwoven material manufacturing process to joinsome of the fibers 219 of a fibrous web together to form the nonwovenmaterials and provide them with integrity. Typically, these normalcalendar or point bonds are created by conveying the fibrous web througha nip between a calendar roll having plurality of nubs (that create thebonds) and an anvil roll, as is generally known in the art. The normalcalendar or point bonded nonwoven materials for the laminates of thepresent disclosure may comprise continuous fiber nonwoven materials(e.g., spunbond nonwoven materials) or may comprise carded fibernonwoven materials. The calendar or point bonded nonwoven materials mayalso comprise other types of fibers such as natural fibers (e.g.,cotton) or a blend of natural and synthetic fibers.

In contrast to normal calendar or point bonds, fibers of a fibrous webmay be through-air bonded to form a nonwoven material. Through-airbonding processes create many more and smaller bonds in a nonwovenmaterial compared to normal calendar or point bonds. Typicallythrough-air bonds are created by passing heated or hot air through afibrous web. Through-air bonds are formed where fibers 223 of thefibrous web contact each other, typically by melting of the fiberintersections. Individual through-air bonds are much weaker than normalcalendar or point bonds as these bonds are each formed only between afew fibers (e.g., 2 fibers to 5 fibers). FIG. 22 is a side viewphotograph of a through-air bonded nonwoven material 222 comprising aplurality of through-air bonds 224. FIG. 23 is a cross-sectionalphotograph taken about line 23-23 of FIG. 22. As can be seen in FIG. 23,the through-air bonds 224 occur at, at least some of the fiberintersections and are quite plentiful. The through-air bonded nonwovenmaterials may only comprise fiber to fiber bonds and may not compriseany other bonds. Though-air bonded nonwoven materials for the laminatesof the present disclosure may comprise continuous fiber nonwovenmaterials (e.g., spunbond materials) or may comprise carded fibernonwoven materials. The through-air bonded nonwoven materials may alsocomprise other types of fibers such as natural fibers (e.g., cotton,pulp, bamboo) or a blend of natural and synthetic fibers.

Also, in contrast to normal calendar or point bonds, fibers of a fibrousweb may be lightly calendar or point bonded to form a nonwoven material.In such an instance, nubs of a bonding roll may apply less pressure tothe fibrous web than normal calendar or point bonds (i.e., FIG. 21). Byapplying less pressure to the fibrous web, the fibrous web is lessdensified than normal calendar or point bonds and forms lightly bondedcalendar or point bonds. Fibers within the lighted bonded calendar orpoint bonds are able to break free from or move within the bonds morethan fibers within the normal calendar or point bonds duringthree-dimensional element formation. Typically, fibers within normalcalendar or point bonds break during three-dimensional element formationcausing loose fiber ends and reducing softness. By having lightly bondedcalendar or point bonds, fiber breakage may be reduced and improvedsoftness may be achieved.

Owing to the nature of through-air bonds and/or lightly bonded calendaror point bonds, these nonwoven materials may allow for more fibermovement when creating three-dimensional elements therein. Statedanother way, through-air bonds and/or lightly bonded calendar or pointbonds in a nonwoven material may allow basis weight of the nonwovenmaterials to be shifted proximate to or adjacent to thethree-dimensional elements. This fiber movement and/or basis weightshifting is believed to be due to through-air bonds between individualfibers breaking upon application of an applied strain (i.e.,three-dimensional element formation). The same fiber movement may benoticed in nonwoven materials that comprise lightly bonded calendar orpoint bonds. The same phenomenon has not been seen in normal calendar orpoint bonded nonwoven materials owing to the strength of the calendar orpoint bonds. As such, the substrates and/or laminates of the presentdisclosure may employ at least one through-air bonded nonwoven materialor at least one nonwoven material comprising lightly bonded calendar orpoint bonds. The second or additional materials of a laminate may bethrough-air bonded nonwoven materials, nonwoven materials comprisinglightly bonded calendar or point bonds, or may be normal calendar orpoint bonded nonwoven materials. The through-air bonded nonwovenmaterials may be bonded at low temperatures (i.e., gas passing throughthe nonwoven materials is of a low temperature), thereby creating lowstrength bonds between individual fibers. This may allow the fibers toessentially pull out of the bonds and allow for improved fiber mobilitycompared to normal calendar or point bonds.

Referring again to FIG. 16, the second nonwoven material 204 may be athrough-air bonded nonwoven material or a nonwoven material comprisinglightly bonded calendar or point bonds. As such, when thethree-dimensional elements 208 are formed in the laminate 200, fibers ofthe second nonwoven material 204 may move into the three-dimensionalelements 208 and leave a low basis weight, increased permeability region212 adjacent to or proximate to the three-dimensional elements 208. Asstated above, this fiber movement out of the increased permeabilityregions 212 into the three-dimensional elements 208 is believed to bemade possible by the use of the through-air bonded nonwoven materials ornonwoven materials comprising lightly bonded calendar or point bonds.The first nonwoven material 202 may be a normal calendar or point bondednonwoven material, may be a through-air bonded nonwoven material, or maybe a nonwoven material comprising lightly bonded calendar or pointbonds. When referring to an increased permeability region herein, itwill be understood that even if the low basis weight area is only in oneof the nonwoven materials, the overall laminate will still have anincreased permeability in that area.

Referring to FIG. 17, the first and/or third nonwoven materials maycomprise through-air bonded nonwoven materials, normal calendar or pointbonded nonwoven materials, or nonwoven materials comprising lightedbonded calendar or point bonds. If the first and/or third nonwovenmaterials comprise through-air bonded nonwoven materials or nonwovenmaterials comprising lighted bonded calendar or point bonds, increasedpermeability regions may be created in the first and third nonwovenmaterials in areas overlapping the increased permeability regions 212 inFIG. 17. The same may apply to the second nonwoven material of FIG. 19.

The first nonwoven material 202 of FIG. 18 may be a through-air bondednonwoven material or nonwoven material comprising lightly bondedcalendar or point bonds. The second nonwoven material 204 of FIG. 18 maybe a through-air bonded nonwoven material, a nonwoven materialcomprising lightly bonded calendar or point bonds, or a normal calendaror point bonded material.

The increased permeability regions allow for faster bodily exudateacquisition, especially in combination with the three-dimensionalelements. Consumers desire bodily exudates to be quickly removed from awearer-facing surface of an absorbent article and quickly absorbed bythe absorbent articles. The increased permeability regions may even helpbodily exudate acquisition when the first nonwoven material 202 is morehydrophobic than the second nonwoven material 204. A hydrophobicwearer-facing layer (e.g., first nonwoven material 202) may be desirableto minimize rewet and maintain a clean/dry surface for the wearer,however bodily exudate acquisition speeds may typically be slower. Oftenapertures are added to nonwoven materials to address this. Sometimes,however, texture is desired over apertures for softness, for theperception or reality of bodily exudates being able to come back upthrough the apertures, and/or for having texture to wipe the body, butstill larger gushes of bodily exudates are required to be absorbed.

Referring generally to FIGS. 16-19, the first nonwoven material 202 maybe hydrophobic, while the second nonwoven material 204 may behydrophilic. In another instance, the first nonwoven material 202 may bemore hydrophobic, or more hydrophilic, than the second nonwoven material204. Likewise, the first nonwoven material 202 may have a differentcontact angle than the second nonwoven material 204. In other instances,both of the first nonwoven material 202 and the second nonwoven material204 may be hydrophilic to the same degree or to different degrees.Referring specifically to FIG. 17, the third nonwoven material 206 maybe more hydrophilic than the first and second nonwoven materials 202,204. Referring to FIGS. 16A and 19A, the substrates 201 may behydrophobic or hydrophilic as desired for an intended use.

Referring to FIGS. 16 and 18 generally, the land areas 210 of thelaminate 200 may have a first basis weight and the increasedpermeability regions 212 of the laminate 200 may have a second basisweight. The first basis weight may be greater than the second basisweight. The three-dimensional elements 208 of the laminate 200 may havea third basis weight. The third basis weight may be less than the firstbasis weight, but greater than the second basis weight. Basis weight inthis paragraph refers to total basis weight of all of the layers (exceptin the three-dimensional elements of FIGS. 16 and 18 since only onelayer is present).

With respect to the laminate 200 of FIGS. 16 and 18, the second basisweight may be less than 50% to less than 5%, less than 45% to less than5%, less than 40% to less than 5%, less than 35% to less than 5%, lessthan 30% to less than 5%, less than 25% to less than 5%, less than 20%to less than 5%, less than 15% to less than 5%, less than 50% to lessthan 10%, less than 45% to less than 10%, less than 40% to less than10%, less than 35% to less than 10%, less than 30% to less than 10%,less than 25% to less than 10%, less than 20% to less than 10%, lessthan 15% to less than 10%, of the first basis weight, specificallyreciting all 0.1% increments within the specified ranges and all rangesformed therein or thereby. All basis weight percentages discussed hereinare according to the Micro-CT Test herein.

Referring to FIGS. 17 and 19 generally, the land areas 210 of thelaminate 200 may have a first basis weight and the increasedpermeability regions 212 of the laminate 200 may have a second basisweight. The first basis weight may be greater than the second basisweight. The three-dimensional elements 208 of the laminate 200 may havea third basis weight. The third basis weight may be the same orsubstantially the same as the first basis weight and may be greater thanthe second basis weight. Basis weight in this paragraph refers to totalbasis weight of all of the layers.

With respect to the laminate 200 of FIGS. 17 and 19, the second basisweight may be less than 50% to less than 5%, less than 45% to less than5%, less than 40% to less than 5%, less than 35% to less than 5%, lessthan 30% to less than 5%, less than 25% to less than 5%, less than 20%to less than 5%, less than 15% to less than 5%, less than 50% to lessthan 10%, less than 45% to less than 10%, less than 40% to less than10%, less than 35% to less than 10%, less than 30% to less than 10%,less than 25% to less than 10%, less than 20% to less than 10%, lessthan 15% to less than 10%, of the first and/or third basis weights,specifically reciting all 0.1% increments within the specified rangesand all ranges formed therein or thereby. All basis weight percentagesdiscussed herein are according to the Micro-CT Test herein.

Referring to FIGS. 16-19A generally, the land areas 210 or 210′ of thenonwoven material having the increased permeability regions (212 or212′) may have a first basis weight and the increased permeabilityregions 212 of the nonwoven material 204 may have a second basis weight.The first basis weight may be greater than the second basis weight. Thethree-dimensional elements 208 of the second nonwoven materials 204 mayhave a third basis weight. The third basis weight may be the same orsubstantially the same as the first basis weight and may be greater thanthe second basis weight.

With respect to the nonwoven material discussed in the precedingparagraph, the second basis weight may be less than 50% to less than 5%,less than 45% to less than 5%, less than 40% to less than 5%, less than35% to less than 5%, less than 30% to less than 5%, less than 25% toless than 5%, less than 20% to less than 5%, less than 15% to less than5%, less than 50% to less than 10%, less than 45% to less than 10%, lessthan 40% to less than 10%, less than 35% to less than 10%, less than 30%to less than 10%, less than 25% to less than 10%, less than 20% to lessthan 10%, less than 15% to less than 10%, of the first and/or thirdbasis weights, specifically reciting all 0.1% increments within thespecified ranges and all ranges formed therein or thereby. All basisweight percentages discussed herein are according to the Micro-CT Testherein.

The fibers of the nonwoven material disclosed herein may comprise resinscomprising polyolefins, PP, PE, copolymers, polyesters, bio-sourcedmaterials, natural materials, or blends of the same.

The fibers of the nonwoven materials disclosed herein may comprisebicomponent fibers, such as PP/PE, PET/PE, PET/coPET, or PLA/PE, forexample. The bicomponent fibers may have a core/sheath configuration, aconcentric or eccentric core/sheath configuration, an islands-in-the-seaconfiguration, and/or any other suitable bicomponent configurationswhere at least a portion of a surface of the fibers comprises a lowermelting component, for example.

As used herein, the term “non-round fiber(s)” describes fibers having anon-round cross-section, and includes “shaped fibers” and “capillarychannel fibers.” Such fibers may be solid or hollow, and they may betri-lobal, delta-shaped, and may be fibers having capillary channels ontheir outer surfaces. The capillary channels may be of variouscross-sectional shapes such as “U-shaped”, “H-shaped”, “C-shaped” and“V-shaped”. The fibers may be round, hollow, or shaped, such astri-lobal, ribbon, capillary channel fibers (e.g., 4DG). The fibers maycomprise microfibers or nanofibers. The fibers may also have roundcross-sectional shapes.

The basis weight of the overall substrates or laminates of the presentdisclosure may vary according to the intended purpose of the substratesor laminates. The basis weight of an overall laminate or substrate maybe in the range of about 10 gsm (grams per square meter) to about 120gsm, about 10 gsm to about 100 gsm, about 10 gsm to about 100 gsm, about15 gsm to about 75 gsm, about 15 gsm to about 65 gsm, about 15 gsm toabout 50 gsm, about 20 gsm to about 40 gsm, specifically reciting all0.1 gsm increments within the specified ranges and all ranges formedtherein or thereby.

The various nonwoven materials of the laminates discussed herein mayhave the same color or different colors. In some instances, a firstnonwoven material may be a first, non-white color, and a second nonwovenmaterial may be white or may be a second non-white color. As an example,the first nonwoven material may be white and the second nonwovenmaterial may be teal, or vice versa. As another example, the firstnonwoven material may be teal and the second nonwoven material may beblue, or vice versa. The substrates discussed herein may be a non-whitecolor as well.

The various nonwoven materials of a laminate may have differentopacities. For instance, a first nonwoven material of a laminate mayhave a different opacity as a second nonwoven material of the laminate.The first and second nonwoven materials may have an opacity differencein the range of about 10% to about 70%, about 15% to about 60%, about15% to about 50%, about 20% to about 50%, specifically reciting all 0.1%increments within the specified ranges and all ranges formed therein orthereby.

FIGS. 24 and 25 illustrate another laminate 300 of the presentdisclosure, wherein portions of the first nonwoven material 302 extendthrough openings 307 in the second nonwoven material 304 to formthree-dimensional elements 308 in the laminate 300. It is to berecognized that the second nonwoven material 304 may instead extendthrough openings in the first nonwoven material 302 depending on whetherit is desired to have the three-dimensional elements 308 facing upwardlyor downwardly. FIG. 24 is a bottom perspective view of the laminate 300.FIG. 25 is an exploded view of the circle 25 of FIG. 24. The laminate300 may also comprise land areas 310 and increased permeability regions312 (similar to that described above with respect to increasedpermeability regions 212). Low basis weight areas of the increasedpermeability regions 312 may occur in the first nonwoven material 302 inthe example of FIGS. 24 and 25. As such, the first nonwoven material 302may be a through-air bonded material, such as a carded through-airbonded material, for example. The first nonwoven material 302 may alsobe a nonwoven material comprising lightly bonded calendar or pointbonds. The second nonwoven material 304 may be a through-air bondedmaterial or a calendar or point bonded material. Additional materialsmay also be provided in the laminate.

Suitable example processes for producing the laminates and substrates ofthe present disclosure are detailed in U.S. Pat. No. 7,553,532 to Turneret al (see e.g., FIGS. 7-10 and associated disclosure).

In view of the fiber movement allowed by the use of the first nonwovenmaterial 302 that is a through-air bonded nonwoven material or nonwovenmaterial comprising lightly bonded calendar or point bonds, fibers ofthe three-dimensional elements may have substantially constant fiberdiameters. Fibers in three-dimensional elements without the use of athrough-air bonded nonwoven material or nonwoven material comprisinglightly bonded calendar or point bonds, typically have thinned or brokenfibers in three-dimensional elements owing to the lack of fiber movementallowed, such as in normal calendar or point bonded nonwoven materials.By allowing for fiber movement (e.g., using through-air bonded nonwovenmaterials), there are many more types of fibers possible, since thefibers do not need to be extensible to stretch or thin during thethree-dimensional element formation. For example, PE/PET fibers are nottypically extensible and may break upon applied strain if the fibers arenot able to pull out of the bond sites. A further advantage of using athrough-air bonded material or a nonwoven material comprising lightlybonded calendar or point bonds as the first nonwoven material may befuller tufts with unbroken fibers, or less broken fibers in the tuftscompared to a normal calendar or point bonded nonwoven material.

Sum of Bond Strength vs. Sum of Fiber Breakage Strength

The substrates and/or laminates comprising a nonwoven materialcomprising the increased permeability regions may comprise bonds joiningthe fibers. The nonwoven material may be a through-air bonded nonwovenmaterial or a nonwoven material comprising lightly bonded calendar orpoint bonds. The bonds may each have a bond strength. The fibers mayeach have a fiber yield or breakage strength. A sum of the bondstrengths in an area of the nonwoven material may be less than a sum ofthe fiber yield or breakage strengths in the area of the nonwovenmaterial. Individual bonds strengths may be less than individual fiberyield or breakage strengths to allow individual bonds to come apart andenable individual fibers to move vs. stretch (i.e., yield) or break. Thearea may at least partially or fully coincide with the increasedpermeability regions. By having the sum of the bonds strengths beingless than the sum of the fiber breakage strengths, it is believed thatthe bonds in the area typically break before the fibers in the area,thereby leading to improved fiber movement when three-dimensionalelements are created, and, thereby reducing fiber breakage duringthree-dimensional element creation.

Films

A laminate may comprise a film in combination with a through-air bondednonwoven material or nonwoven material comprising lightly bondedcalendar or point bonds. The film may be the first layer and thethrough-air bonded nonwoven material or nonwoven material comprisinglightly bonded calendar or point bonds may be the second layer. Thelaminate may comprise land areas and three-dimensional elements in bothlayers and increased permeability regions in the through-air bondednonwoven material or nonwoven material comprising lightly bondedcalendar or point bonds.

TEST METHODS

All samples are conditioned in an environment maintained at 23±2° C. and50±2% relative humidity for 24 hours prior to testing.

Fiber Diameter and Denier Test

The diameter of fiber in a sample of a nonwoven material is determinedby using a Scanning Electron Microscope (SEM) and image analysissoftware. A magnification of 500 to 10,000 times is chosen such that thefilaments are suitably enlarged for measurement (such that at least 3-5pixels cross the diameter (“width”) of a fiber). The samples aresputtered with gold or a palladium-gold compound to avoid electriccharging and vibrations of the fibers in the electron beam. A manualprocedure for determining the fibers diameters is used. Using a mouseand a cursor tool, the edge of a randomly selected fiber is sought andthen measured across its width (i.e., perpendicular to fiber directionat that point) to the other edge of the fiber. For non-circular fibers,the area of the cross-section is measured using the image analysissoftware by analyzing the Z-plane cross-sections of the fibers. Theeffective diameter is then calculated by calculating the diameter as ifthe found area was that of a circle. A scaled and calibrated imageanalysis tool provides the scaling to get actual reading in micrometers(μm). Several fibers in the three-dimensional elements of the nonwovenmaterial are thus randomly selected across the sample of the nonwovenmaterial using the SEM. At least two specimens from the nonwovenmaterial in the three-dimensional elements are cut and tested in thismanner. Altogether, at least 100 such measurements are made and then alldata are recorded for statistical analysis. The recorded data are usedto calculate average (mean) of the fiber diameters, standard deviationof the fiber diameters, and median of the fiber diameters. Anotheruseful statistic is the calculation of the amount of the population offiber that is below a certain upper limit. To determine this statistic,the software is programmed to count how many results of the fiberdiameters are below an upper limit and that count (divided by totalnumber of data and multiplied by 100%) is reported in percent as percentbelow the upper limit, such as percent below 1 micrometer diameter or%-submicron, for example.

If the results are to be reported in denier, then the followingcalculations are made.

Fiber Diameter in denier=Cross-sectional area (in m2)*density (inkg/m3)*9000 m*1000 g/kg.

For round fibers, the cross-sectional area is defined by the equation:

A=π*(D/2)̂2.

The density for polypropylene, for example, may be taken as 910 kg/m3.

Given the fiber diameter in denier, the physical circular fiber diameterin meters (or micrometers) is calculated from these relationships andvice versa. We denote the measured diameter (in microns) of anindividual circular fiber as D.

In case the fiber have non-circular cross-sections, the measurement ofthe fiber diameter is determined as and set equal to the hydraulicdiameter, as discussed above.

The fiber cross sectional shape may be determined from the above imagesof the cross-sections in the Z-plane as well. The nonwoven fibers nearthe first surface of the nonwoven material should be evaluated forcross-sectional shape. The cross-sectional shape of the fibers near thefirst surface of the nonwoven material should be recorded. Nonwovenfibers near the second surface of the nonwoven material should beevaluated for cross-sectional shape. The cross-sectional shape of thefibers near the second surface of the nonwoven material should berecorded.

Micro-CT Test

The micro-CT measurement method calculates basis weight values withindifferent regions of a laminate or substrate sample, such asthree-dimensional elements, lands areas, and increased permeabilityregions formed adjacent to the three-dimensional elements and positionedintermediate at least some of the land areas and at least some of thethree-dimensional elements. Basis weight is based on analysis of a 3Dx-ray sample image obtained on a micro-CT instrument (a suitableinstrument is the Scanco μCT 50 available from Scanco Medical AG,Switzerland, or equivalent). The micro-CT instrument is a cone beammicrotomograph with a shielded cabinet. A maintenance free x-ray tube isused as the source with an adjustable diameter focal spot. The x-raybeam passes through the sample, where some of the x-rays are attenuatedby the sample. The extent of attenuation correlates to the mass ofmaterial the x-rays have to pass through. The transmitted x-rayscontinue on to the digital detector array and generate a 2D projectionimage of the sample. A 3D image of the sample is generated by collectingseveral individual projection images of the sample as it is rotated,which are then reconstructed into a single 3D image. The instrument isinterfaced with a computer running software to control the imageacquisition and save the raw data. The 3D image is then analyzed usingimage analysis software (suitable image analysis software are MATLABavailable from The Mathworks, Inc., Natick, Mass., and Avizo Liteavailable from Visualization Sciences Group/FEI Company, Burlington,Mass., or equivalents) to measure the basis weight of regions within thelaminate or substrate sample.

Sample Preparation

To obtain a sample for measurement, lay a single layer of the dry sampleout flat and die cut/punch out a circular piece with a diameter ofapproximately 20 mm. If the sample is in the form of a laminate, diecut/punch out a circular sample with a diameter of approximately 20 mmthat includes all layers of the laminate. The laminate sample may beanalyzed either as the intact multi-layer structure, or separated intoindividual substrate layers for analysis, so long as separation of thelaminate layers does not physically deform or alter the structure of theindividual layer.

If the substrate/laminate is a layer of an absorbent article, forexample a topsheet, backsheet nonwoven, acquisition layer, distributionlayer, or other component layer, tape the absorbent article to a rigidflat surface in a planar configuration. Carefully separate theindividual substrate/laminate from the absorbent article. A scalpeland/or cryogenic spray (such as Cyto-Freeze, Control Company, HoustonTex.) can be used to remove a substrate/laminate from additionalunderlying layers, if necessary, to avoid any longitudinal and lateralextension of the substrate/laminate. Once the substrate/laminate hasbeen removed from the absorbent article, proceed with diecutting/punching out the sample as described above.

If the substrate/laminate is in the form of a wet wipe, open a newpackage of wet wipes and remove the entire stack from the package.Remove a single wipe from the middle of the stack, lay it out flat andallow it to dry completely prior to die cutting/punching out the samplefor analysis.

A sample may be cut from any location containing the regions to beanalyzed. Care should be taken to avoid folds, wrinkles or tears whenselecting a location for sampling.

Image Acquisition

Set up and calibrate the micro-CT instrument according to themanufacturer's specifications. Place the sample into the appropriateholder, between two rings of low density material. This will allow thecentral portion of the sample to lay horizontal and be scanned withouthaving any other materials directly adjacent to its upper and lowersurfaces. Measurements should be taken in this region. The 3D imagefield of view is approximately 15 mm on each side in the XY-plane with aresolution of approximately 3400 by 3400 pixels, and with a sufficientnumber of 4.5 micron thick slices collected to fully include thez-direction of the sample. The reconstructed 3D image resolutioncontains isotropic voxels of 4.5 microns. Images are acquired with thesource at 45 kVp and 88-200 μA with no additional low energy filter.These current and voltage settings may be optimized to produce themaximum contrast in the projection data with sufficient x-raypenetration through the sample, but once optimized held constant for allsubstantially similar samples. A total of 1500 projections images areobtained with an integration time of 500 ms and 4 averages. Theprojection images are reconstructed into the 3D image, and saved in16-bit RAW format to preserve the full detector output signal foranalysis.

Image Processing

The 3D dataset is loaded into the image analysis software, and trimmed(cropped) to a rectangular prism 3D image of the analysis region byremoving the surrounding holder and the low density mounting materialfrom the 3D dataset. Trimming is performed such that the maximum amountof the sample in the analysis region is retained in the 3D image, andthe empty space above and below the sample is minimized. The trimmed 3Dimage is scaled from 16-bit to 8-bit, and thresholded using Otsu'smethod, which calculates the threshold level that minimizes the weightedintra-class variance, to separate and remove the background signal dueto air, but maintain the signal from the fibers within the sample image.

The thresholded 3D image is oriented so that the upper surface is asclose to parallel with the XY-plane as possible.

A Basis Weight image is generated from the thresholded 3D image. Togenerate this image, the value for each voxel in an XY-plane slice issummed with all of its corresponding voxel values in the otherz-direction slices containing signal from the sample. This creates a 2Dimage where each pixel now has a value equal to the cumulative signalthrough the entire sample.

In order to convert the raw data values in the Basis Weight Image intoreal values, a basis weight calibration curve is generated. Obtain asubstrate/laminate that is of substantially similar composition to thesample being analyzed and has a uniform basis weight. Follow theprocedures described above to obtain at least ten replicate samples ofthe calibration curve substrate. Accurately measure the basis weight, bytaking the mass to the nearest 0.0001 g and dividing by the sample areaand converting to grams per square meter (gsm), of each of the singlelayer calibration samples and calculate the average to the nearest 0.01gsm. Following the procedures described above, acquire a micro-CT imageof a single layer of the calibration sample substrate. Following theprocedure described above, process the micro-CT image, and generate aBasis Weight Image containing raw data values. The real basis weightvalue for this sample is the average basis weight value measured on thecalibration samples. Next, stack two layers of the calibration sampleson top of each other, and acquire a micro-CT image of the two layers ofcalibration material. Generate a basis weight raw data image of bothlayers together, whose real basis weight value is equal to twice theaverage basis weight value measured on the calibration samples. Repeatthis procedure of stacking single layers of the calibration substrate,acquiring a micro-CT image of all of the layers, generating a raw databasis weight image of all of the layers, the real basis weight value ofwhich is equal to the number of layers times the average basis weightvalue measured on the calibration samples. A total of at least fourdifferent basis weight calibration images are obtained. The basis weightvalues of the calibration samples must include values above and belowthe basis weight values of the original sample being analyzed to ensurean accurate calibration. The calibration curve is generated byperforming a linear regression on the raw data versus the real basisweight values for the four calibration samples. This linear regressionmust have an R² value of at least 0.95, if not repeat the entirecalibration procedure. This calibration curve is now used to convert theraw data values into real basis weights.

Micro-CT Basis Weight

Begin by identifying the region to be analyzed. A region to be analyzedmay be a three-dimensional element, a lands area, or an increasedpermeability region formed adjacent to a three-dimensional element andpositioned intermediate at least some of the land areas and at leastsome of three-dimensional elements. Next, identify the boundary of theregion to be analyzed. Once the boundary of the region has beenidentified, draw an oval or circular “region of interest” (ROI) withinthe interior of the region. The ROI should have an area of at least 0.1mm², and be selected to measure an area with basis weight valuesrepresentative of the identified region. Calculate the average basisweight within the ROI. Record this value as the region's basis weight tothe nearest 0.01 gsm.

EXAMPLE

In this example, a two layer nonwoven laminate of the present disclosurewas compared to a two layer comparative example laminate. A single layersubstrate of the present disclosure was also compared to a single layercomparative example substrate. Measurements were taking according to theMicro-CT Test herein. Measurements were taken on the two layer laminate(laminates herein) and on only the bottom layer (substrates herein) ofthe example nonwoven material and the comparative example nonwovenmaterial.

The example nonwoven material of the present disclosure had a first(top) layer and a second (bottom) layer. The top layer was a normalcalendar bonded, 25 gsm nonwoven material of polyethylene/polypropylenesheath/core bicomponent spunbond fibers. The bottom layer was athrough-air bonded, 25 gsm nonwoven material of carded hydrophilicpolyethylene fibers. The layers were tufted together (see e.g., FIG. 24)using a 0.060 pitch tooling at a depth of engagement of 0.115 inches anda line speed of 1,000 feet per minute. Example suitable tooling isillustrated in FIGS. 7-10 of U.S. Pat. No. 7,553,532 to Turner et al.

The comparative example material had a first (top) layer and a second(bottom) layer. The top layer was a normal calendar bonded, 25 gsmnonwoven material of polyethylene/polypropylene sheath/core bicomponentspunbond fibers. The bottom layer was a normal calendar bonded,hydrophilic 25 gsm nonwoven material of polyethylene/polypropylenesheath/core bicomponent spunbond fibers.

The top layers were the same in both the example nonwoven material andin the comparative example nonwoven material.

The example of the present disclosure nonwoven material comprisingincreased permeability regions is illustrated in FIG. 26. Thecomparative example material that does not comprise increasedpermeability regions and that does comprise calendar bonds isillustrated in FIG. 27.

Increased Land Area Permeability Region Basis Basis Basis Weight Weight(gsm) Weight (gsm) Change Two Layer (Laminate) Present Disclosure 50.236.7 23% Example Bico/Carded HL Comparative Example 47.4 42.8 9.6% Bico/Bico Lower Layer Only (Substrate) Present Disclosure 24.6 12.7 48%Example Bico/Carded HL Comparative Example 21.7 17.1 21% Bico/Bico-PriorArt

Combinations

Paragraph 1. A liquid permeable laminate for an absorbent article, thelaminate comprising:

a first nonwoven material;

a second nonwoven material, wherein the second nonwoven materialcomprises through-air bonds;

portions of the second nonwoven material extending into or through thefirst nonwoven material to form three-dimensional elements in thelaminate;

land areas in the laminate in areas free of the three-dimensionalelements;

wherein, in the land areas, the laminate has a first basis weight,according to the Micro-CT Test;

increased permeability regions formed in the laminate adjacent tothree-dimensional elements and intermediate at least some of the landareas and at least some of the three-dimensional elements;

wherein the increased permeability regions have a second basis weight inthe range of less than 50% to less than 5% of the first basis weight ofthe land areas, according to the Micro-CT Test.

Paragraph 2. The laminate for an absorbent article of Paragraph 1,wherein the first nonwoven material has a third basis weight in the landareas, wherein the first nonwoven material has a fourth basis weight inthe increased permeability regions, and wherein the third basis weightis substantially the same as the fourth basis weight.Paragraph 3. The laminate for an absorbent article of Paragraph 2,wherein the second nonwoven material has a fifth basis weight in theland areas, wherein the second nonwoven material has a sixth basisweight in the increased permeability regions, and wherein the sixthbasis weight is in the range of less than 75% to less than 25% of thefifth basis weight, according to the Micro-CT Test.Paragraph 4. The laminate for an absorbent article of any one of thepreceding Paragraphs, wherein the second nonwoven material is free ofcalendar or point bonds and comprises only fiber to fiber bonds.Paragraph 5. The laminate for an absorbent article of any one of thepreceding Paragraphs, wherein the portions of the second nonwovenmaterial extend through the first nonwoven material to form thethree-dimensional elements in the laminate, and wherein a first surfaceof the laminate comprises portions of the first nonwoven material andportions of the second nonwoven material.Paragraph 6. The laminate for an absorbent article of any one of thepreceding Paragraphs, wherein the first nonwoven material comprisescalendar bonds.Paragraph 7. The laminate for an absorbent article of any one ofParagraphs 1-5, wherein the first nonwoven material comprisesthrough-air bonds, and wherein the first nonwoven material is free ofcalendar or point bonds and comprises only fiber to fiber bonds.Paragraph 8. The laminate for an absorbent article of any one of thepreceding Paragraphs, wherein the first nonwoven material comprisescontinuous fibers.Paragraph 9. The laminate for an absorbent article of any one of thepreceding Paragraphs, wherein the first nonwoven material has adifferent contact angle than the second nonwoven material.Paragraph 10. The laminate for an absorbent article of any one of thepreceding Paragraphs, wherein the second nonwoven material comprisescarded fibers.

Paragraph 11. The laminate for an absorbent article of any one ofParagraphs 1-9, wherein the second nonwoven material comprisescontinuous fibers.

Paragraph 12. The laminate for an absorbent article of any one of thepreceding Paragraphs, wherein fibers of the second nonwoven materialhave a substantially constant fiber diameter in the three-dimensionalelements.Paragraph 13. The laminate for an absorbent article of any one of thepreceding Paragraphs, wherein the first nonwoven material and/or thesecond nonwoven material comprises bicomponent fibers.Paragraph 14. The laminate for an absorbent article of any one of thepreceding Paragraphs, wherein the second basis weight of the increasedpermeability regions is in the range of less than 30% to less than 5% ofthe first basis weight of the land areas, according to the Micro-CTTest.Paragraph 15. The laminate for an absorbent article of any one of thepreceding Paragraphs, wherein the first nonwoven material has a firstopacity, wherein the second nonwoven material has a second opacity, andwherein the first opacity is different than the second opacity.Paragraph 16. The laminate for an absorbent article of any one of thepreceding Paragraphs, wherein the first nonwoven material has a firstcolor, wherein the second nonwoven material has a second color, andwherein the first color is different than the second color.Paragraph 17. An absorbent article comprising:

the laminate of any one of the preceding Paragraphs;

a liquid impermeable backsheet;

an absorbent core disposed at least partially intermediate the laminateand the liquid impermeable backsheet.

Paragraph 18. The absorbent article of Paragraph 17, wherein thelaminate forms the topsheet in the absorbent article.Paragraph 19. The absorbent article of Paragraph 17, wherein thelaminate forms the topsheet and the acquisition layer or secondarytopsheet in the absorbent article.Paragraph 20. The absorbent article of any one of Paragraphs 17-19,wherein the absorbent article is a diaper or pant, and wherein thediaper or the pant comprises leg cuffs.Paragraph 21. The absorbent article of any one of Paragraphs 17-19,wherein the absorbent article is a sanitary napkin.Paragraph 22. A liquid permeable laminate for an absorbent article, thelaminate comprising:

a first material;

a second nonwoven material, wherein the second nonwoven materialcomprises through-air bonds;

portions of the second nonwoven material extending into or through thefirst material to form three-dimensional elements in the laminate;

land areas in the laminate in areas free of the three-dimensionalelements;

wherein, in the land areas, the laminate has a first basis weight,according to the Micro-CT Test;

increased permeability regions formed in the laminate adjacent tothree-dimensional elements and intermediate at least some of the landareas and at least some of the three-dimensional elements;

wherein the increased permeability regions have a second basis weight inthe range of less than 50% to less than 5% of the first basis weight ofthe land areas, according to the Micro-CT Test.

Paragraph 23. The laminate for an absorbent article of Paragraph 22,wherein the first material is a film.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

All documents cited herein, including any cross referenced or relatedpatent, patent publication, or patent application, is herebyincorporated by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests, or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular forms of the present disclosure have been illustratedand described, those of skill in the art will recognize that variousother changes and modifications can be made without departing from thespirit and scope of the invention. It is therefore intended to cover inthe appended claims all such changes and modifications that are withinthe scope of the present disclosure.

What is claimed is:
 1. A liquid permeable laminate for an absorbentarticle, the laminate comprising: a first nonwoven material; a secondnonwoven material, wherein the second nonwoven material comprisesthrough-air bonds; portions of the second nonwoven material extendinginto or through the first nonwoven material to form three-dimensionalelements in the laminate; land areas in the laminate in areas free ofthe three-dimensional elements; wherein, in the land areas, the laminatehas a first basis weight, according to the Micro-CT Test; and increasedpermeability regions formed in the laminate adjacent to at least some ofthe three-dimensional elements and intermediate at least some of theland areas and at least some of the three-dimensional elements; whereinthe increased permeability regions have a second basis weight in therange of 50% to 5% less than the first basis weight of the land areas,according to the Micro-CT Test.
 2. The laminate for an absorbent articleof claim 1, wherein the first nonwoven material has a third basis weightin the land areas, wherein the first nonwoven material has a fourthbasis weight in the increased permeability regions, and wherein thethird basis weight is substantially the same as the fourth basis weight.3. The laminate for an absorbent article of claim 2, wherein the secondnonwoven material has a fifth basis weight in the land areas, whereinthe second nonwoven material has a sixth basis weight in the increasedpermeability regions, and wherein the sixth basis weight is in the rangeof 75% to 25% less than the fifth basis weight, according to theMicro-CT Test.
 4. The laminate for an absorbent article of claim 1,wherein the second nonwoven material is free of calendar or point bondsand comprises only fiber to fiber bonds.
 5. The laminate for anabsorbent article of claim 1, wherein the portions of the secondnonwoven material extend through the first nonwoven material to form thethree-dimensional elements in the laminate, and wherein a first surfaceof the laminate comprises portions of the first nonwoven material andportions of the second nonwoven material.
 6. The laminate for anabsorbent article of claim 1, wherein the first nonwoven materialcomprises calendar bonds.
 7. The laminate for an absorbent article ofclaim 1, wherein the first nonwoven material comprises through-airbonds, and wherein the first nonwoven material is free of calendar orpoint bonds and comprises only fiber to fiber bonds.
 8. The laminate foran absorbent article of claim 1, wherein the first nonwoven materialcomprises continuous fibers.
 9. The laminate for an absorbent article ofclaim 1, wherein the first nonwoven material has a different contactangle than the second nonwoven material.
 10. The laminate for anabsorbent article of claim 1, wherein the second nonwoven materialcomprises carded fibers.
 11. The laminate for an absorbent article ofclaim 1, wherein the second nonwoven material comprises continuousfibers.
 12. The laminate for an absorbent article of claim 1, whereinfibers of the second nonwoven material have a substantially constantfiber diameter in the three-dimensional elements.
 13. The laminate foran absorbent article of claim 1, wherein the first nonwoven materialand/or the second nonwoven material comprises bicomponent fibers. 14.The laminate for an absorbent article of claim 1, wherein the secondbasis weight of the increased permeability regions is in the range of30% to 5% less than the first basis weight of the land areas, accordingto the Micro-CT Test.
 15. The laminate for an absorbent article of claim1, wherein the first nonwoven material has a first opacity, wherein thesecond nonwoven material has a second opacity, and wherein the firstopacity is different than the second opacity.
 16. The laminate for anabsorbent article of claim 1, wherein the first nonwoven material has afirst color, wherein the second nonwoven material has a second color,and wherein the first color is different than the second color.
 17. Anabsorbent article comprising: the laminate of claim 1; a liquidimpermeable backsheet; an absorbent core disposed at least partiallyintermediate the laminate and the liquid impermeable backsheet.
 18. Theabsorbent article of claim 17, wherein the laminate forms the topsheetin the absorbent article, or wherein the laminate forms the topsheet andthe acquisition layer or secondary topsheet in the absorbent article.19. The absorbent article of claim 17, wherein the absorbent article isa diaper or pant, and wherein the diaper or the pant comprises legcuffs.
 20. The absorbent article of claim 17, wherein the absorbentarticle is a sanitary napkin.
 21. A liquid permeable laminate for anabsorbent article, the laminate comprising: a first material; a secondnonwoven material, wherein the second nonwoven material comprisesthrough-air bonds; portions of the second nonwoven material extendinginto or through the first material to form three-dimensional elements inthe laminate; land areas in the laminate in areas free of thethree-dimensional elements; wherein, in the land areas, the laminate hasa first basis weight, according to the Micro-CT Test; and increasedpermeability regions formed in the laminate adjacent tothree-dimensional elements and intermediate at least some of the landareas and at least some of the three-dimensional elements; wherein theincreased permeability regions have a second basis weight in the rangeof 50% to 5% less than the first basis weight of the land areas,according to the Micro-CT Test.
 22. The laminate for an absorbentarticle of claim 21, wherein the first material is a film.